Study on Effects of Parallel Ultrasonic Vibration-assisted Cutting on Surface Integrity of Titanium Alloy Shafts

doi:10.3969/j.issn.1004-132X.2026.03.022

Abstract

Abstract:

Considering the difficulties in machining surface quality assurance of titanium alloy shaft parts， a parallel ultrasonic vibration cutting method was proposed based on ultrasonic vibration with two tools cutting synergy. The parallel ultrasonic vibration cutting principles and cutting modes were analyzed， and the tool-workpiece trajectory and separation cutting conditions were studied. The effects of four types of cutting processes including the parallel ultrasonic vibration cutting and the single-tool conventional cutting， the conventional cutting with two tools （parallel cutting）， and the single-tool ultrasonic vibration cutting， on their surface integrity （i.e.， surface roughness and machined surface morphology， surface residual stress， microstructure and surface hardness） were studied. The experimental results indicate that the parallel ultrasonic vibration cutting and the single-tool ultrasonic vibration cutting significantly benefit to reduce the surface roughness of the machined surfaces， to increase the thickness of the deformed layers and the surface hardness， resulting in high surface residual stress. The parallel cutting and parallel ultrasonic vibration cutting may reduce the surface residual stress but increase the surface roughness. Therefore， parallel ultrasonic vibration cutting combines the advantages of parallel cutting and ultrasonic vibration cutting， achieving a lower surface roughness while reducing surface residual stress， increasing surface microhardness and hardening rate， and further enhancing material properties.

Key words: parallel ultrasonic vibration-assisted cutting, surface integrity, titanium alloy, ultrasonic vibration

摘要：

针对钛合金轴类零件加工表面质量保障困难，提出一种基于超声振动的双刀具切削协同的切削方法，即并行超声振动切削。分析了并行超声振动切削原理与切削模式，研究了刀具-工件的运动轨迹和分离切削条件。研究了并行超声振动切削与单刀具普通切削、双刀具普通切削（并行切削）、单刀具超声振动切削等四类切削工艺对其表面完整性（包括表面粗糙度及加工表面形貌、表面残余应力、显微组织与表面硬度）的影响规律。试验结果表明：并行超声振动切削与单刀具超声振动切削显著降低了加工表面粗糙度，增大了变形层厚度和表面硬度，但表面残余应力增大；并行切削和并行超声振动切削的表面残余应力减小，表面粗糙度增大。并行超声振动切削兼具并行切削与振动切削优势，具有较低表面粗糙度的同时减小表面残余应力，提高表面显微硬度及硬化率，进一步增强材料性能。

关键词: 并行超声振动切削, 表面完整性, 钛合金, 超声振动

CLC Number:

LONG Yupeng, CAI Wei, LI Li, PENG Tao, DONG Guojun. Study on Effects of Parallel Ultrasonic Vibration-assisted Cutting on Surface Integrity of Titanium Alloy Shafts[J]. China Mechanical Engineering, 2026, 37(3): 726-734.

龙玉朋, 蔡维, 李丽, 彭涛, 董国军. 并行超声振动切削对钛合金轴表面完整性的影响研究[J]. 中国机械工程, 2026, 37(3): 726-734.

Figures/Tables 13

Fig.1 Principle and modes of PUVC

Fig.2 Shared cutting mode tip trajectory diagram

Fig.3 Two tools separation interval for PUVC［26］

Fig.4 Chip load for PUVC

Fig.5 Dynamic chip thickness of different cutting processes

Tab.1 Technical parameters of CKG7512/2V machines

参数	数值
主轴电机额定功率/（kW）	7.5
伺服电机扭矩/（N·m）	6
最大加工长度/mm	500
最大加工直径/mm	120
托板最大回转直径/mm	160
床身最大回转直径/mm	300
主轴转速/（r·min^-1）	50~3000
X轴快进速度/（mm·min^-1）	8000
Z轴快进速度/（mm·min^-1）	8000
X轴最小设定单位/mm	0.001
Z轴最小设定单位/mm	0.001

Fig.6 Experimental processing device

Tab.2 Experimental conditions and main processing parameters

项目	参数	设置
工件	材料	Ti6Al4V
工件	直径/mm	20
刀具	材料	CVD涂层硬质合金
	前角/（°）	8
	后角/（°）	6
	刀尖圆弧半径/mm	0.4
切削参数	切削速度/（m·min^-1）	37.68
	进给量/（mm·r^-1）	0.01
	切削深度/mm	0.1
振动参数	频率/kHz	20
振动参数	振幅/μm	10
切削液		湿切削

Fig.7 Surface roughness and contour for different processing techniques

Fig.8 Machined surface topography for different cutting processes

Fig.9 Surface residual stresses for different cutting processes

Fig.10 Machined surface deformation layers for different cutting processes

Fig.11 Microhardness of the machined surface for different cutting processes

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